The document describes a case study of a heater revamp project completed by Furnace Improvements Services (FIS) to increase the capacity of platformer and hydrotreater (NHT) heaters. FIS used their patented "Split Flow Technology" to redesign the heaters and increase capacity to 18,000 BPD at a lower cost than conventional methods. The revamp improved the thermal efficiency from 80% to 89% and increased the total heat duty from 119.7 MMBtu/hr to 150.4 MMBtu/hr.
Summary of changes in burner specificationsKapil Batra
Our team at Furnace Improvement Services, New Delhi has compiled an interesting comparison of the changes in Burner Specifications in API-560 Fired Heaters for General Refinery Service over the years. Burner design has evolved a lot due to increasing restriction on NOx emissions. Because of the changes in burner design a lot of additions, modification and deletions have been made in the API 560 standard. We have covered from the 1st API edition made in 1986 to the latest 5th edition published in 2016. We intend to publish more such comparisons from API 560 standard. Please feel free to provide your feedback and comments.
Improve fired heaters performance and reliabiltyAshutosh Garg
Fired heaters are often suffering from high tube metal temperatures and short run lengths. Operators are always worried about hot spots in the furnace. While refineries want to push the heaters hard, the heater starts coking up and very soon, the heater tubes have to be cleaned.
FIS has done extensive research and CFD modelling of heaters in the recent time and has concluded that localized burner flame and hot flue gas currents are responsible for the hot spots on the tubes. FIS has now developed a new patented technology for solving hot spot problems. This technology called Inclined Firing Technology involves orienting the burners at an angle on the floor / wall/ roof to direct the flame away from the tubes. The results of this technology have been extremely good and with a very low investment, the reliability and run length of the heater is improved significantly.
If you are working in refining or petrochemical industry, you need to learn about fired heaters. This paper talks about basic specifications of fired heaters. You can benefit by using good specifications to purchase fired heaters for your next project.
An innovative technology to increase the heater capacity without increasing the coil side pressure drop in fired heaters.
Furnace Improvements has implemented this technology in many fired heaters around the world. This technology is useful specially for Reformer heaters as coil pressure drop is limited for those heaters, typically 2-5 psi.
Fired heaters are used for heating hydrocarbons fluids in the refineries and petrochemical plants. They are used for high temperature heat transfer. In most fired heaters, we are burning fuel gas as source of heat . There are many heaters in the world where liquid fuel is also burnt in the fired heaters to provide the energy, but their number is decreasing due to tighter pollution laws. Heaters that are processing hydrocarbons services are prone to coking and cracking depending upon the nature of the hydrocarbons being processed. Typically heaters may run length of anywhere from 3 months for coking service to 6 years for different services. Heater designers and operators are always faced with the challenge of providing uniform heat transfer to all the tubes. Engineers use equations that assume uniform heat transfer to heater tubes When designing fired heaters. However, in reality, most fired heaters do not experience uniform heat transfer, and as a result, hot spots develop on the tubes. These hot spots cause coking inside the tubes which requires the heater be shutdown periodically to remove the coke and clean the tubes. Any shutdown to clean the tubes in a fired heater causes a substantial production loss. The owners want to extend the run length of fired heaters. Furnace Improvements has developed a new patented firing technology that provides uniform heat transfer to heater tubes. This technology can be applied to most fired heaters. Our patented technology reorients the burners at a slight angle away from the tubes. We are able to direct the hottest part of the flames and flue gases away from the tubes without affecting the heat transfer in any way. FIS has installed this in 5 heaters ranging from 14 MMBtu/hr. to 280 MMBtu/hr. The clients are experiencing significant reduction in tube metal temperatures. This is translating into lower coking rates and higher tube life. We have been able to increase the capacity of the heaters in most of the cases. In one of the case study that has been presented in this heater, the heater duty was increased from 14 MMBtu/hr. to 21 MMBtu/hr. Inclined firing improves the heat transfer to the tubes and makes in uniform.
Summary of changes in burner specificationsKapil Batra
Our team at Furnace Improvement Services, New Delhi has compiled an interesting comparison of the changes in Burner Specifications in API-560 Fired Heaters for General Refinery Service over the years. Burner design has evolved a lot due to increasing restriction on NOx emissions. Because of the changes in burner design a lot of additions, modification and deletions have been made in the API 560 standard. We have covered from the 1st API edition made in 1986 to the latest 5th edition published in 2016. We intend to publish more such comparisons from API 560 standard. Please feel free to provide your feedback and comments.
Improve fired heaters performance and reliabiltyAshutosh Garg
Fired heaters are often suffering from high tube metal temperatures and short run lengths. Operators are always worried about hot spots in the furnace. While refineries want to push the heaters hard, the heater starts coking up and very soon, the heater tubes have to be cleaned.
FIS has done extensive research and CFD modelling of heaters in the recent time and has concluded that localized burner flame and hot flue gas currents are responsible for the hot spots on the tubes. FIS has now developed a new patented technology for solving hot spot problems. This technology called Inclined Firing Technology involves orienting the burners at an angle on the floor / wall/ roof to direct the flame away from the tubes. The results of this technology have been extremely good and with a very low investment, the reliability and run length of the heater is improved significantly.
If you are working in refining or petrochemical industry, you need to learn about fired heaters. This paper talks about basic specifications of fired heaters. You can benefit by using good specifications to purchase fired heaters for your next project.
An innovative technology to increase the heater capacity without increasing the coil side pressure drop in fired heaters.
Furnace Improvements has implemented this technology in many fired heaters around the world. This technology is useful specially for Reformer heaters as coil pressure drop is limited for those heaters, typically 2-5 psi.
Fired heaters are used for heating hydrocarbons fluids in the refineries and petrochemical plants. They are used for high temperature heat transfer. In most fired heaters, we are burning fuel gas as source of heat . There are many heaters in the world where liquid fuel is also burnt in the fired heaters to provide the energy, but their number is decreasing due to tighter pollution laws. Heaters that are processing hydrocarbons services are prone to coking and cracking depending upon the nature of the hydrocarbons being processed. Typically heaters may run length of anywhere from 3 months for coking service to 6 years for different services. Heater designers and operators are always faced with the challenge of providing uniform heat transfer to all the tubes. Engineers use equations that assume uniform heat transfer to heater tubes When designing fired heaters. However, in reality, most fired heaters do not experience uniform heat transfer, and as a result, hot spots develop on the tubes. These hot spots cause coking inside the tubes which requires the heater be shutdown periodically to remove the coke and clean the tubes. Any shutdown to clean the tubes in a fired heater causes a substantial production loss. The owners want to extend the run length of fired heaters. Furnace Improvements has developed a new patented firing technology that provides uniform heat transfer to heater tubes. This technology can be applied to most fired heaters. Our patented technology reorients the burners at a slight angle away from the tubes. We are able to direct the hottest part of the flames and flue gases away from the tubes without affecting the heat transfer in any way. FIS has installed this in 5 heaters ranging from 14 MMBtu/hr. to 280 MMBtu/hr. The clients are experiencing significant reduction in tube metal temperatures. This is translating into lower coking rates and higher tube life. We have been able to increase the capacity of the heaters in most of the cases. In one of the case study that has been presented in this heater, the heater duty was increased from 14 MMBtu/hr. to 21 MMBtu/hr. Inclined firing improves the heat transfer to the tubes and makes in uniform.
New patented split flow technology increases the capacity of catalytic reformer heaters at a fraction of the cost of traditional revamps. Furnace Improvements has installed this technology in four reformer heaters at US refineries. This technology has also been used in several other heaters and one of the main benefits is lower pressure drop at increased capacity thus saving your pump or compressors.
.Coker heaters are one of the most critical heaters in the refineries. The feed is heated to a very high temperature. Run length is one of the important factors for coker heaters. We have worked recently worked on a conventional Coker heater and implemented several improvements while retubing the radiant section.
Air Preheat System Upgrade on Coker HeatersAshutosh Garg
Furnace Improvements design, engineered and revamped the existing air preheat system for a refinery in Houston. This paper was presented at an AIChE conference in October 2019.
Presentation made at the recent Refcomm Conference in Galveston, Texas about the improvements in a crude heater. The client started processing shale crudes and his run length came down to 3 months. FIS modified the heater and increased run length to almost 1.5 years. The project was completed last year. In this presentation, we are showing the CFD modeling of the heater before and after the modifications.
Burner Design, Operation and Maintenance on Ammonia PlantsGerard B. Hawkins
Burner Design, Operation and Maintenance on Ammonia Plants
Brief History
Reformer Burner Types/Design
Types of Reformers
Combustion Characteristics
Excess Air/Heater Efficiency
Maintenance, Good Practice
Low Nox Equipment
Summary
AIChE Smart Stack Damper Design Provides Better Control of Fired HeatersAshutosh Garg
Stack dampers are one of the insignificant yet important component of fired heaters in the refining industry. Over 90% of the heaters in the USA are natural draft and are dependent upon the draft for efficient combustion of fuel gas with air. Stack dampers currently installed are highly oversized and are not able to control draft effectively. Furnace Improvements patent pending design overcomes these limitations and improves the damper control significantly by installing multiple actuators and changing the control characteristics of the dampers.
Combustion sources such as furnaces and fired
heaters play a critical role in the process industry.
Unfortunately, combustion requires large amounts of
fuel (gas, fuel oil). As a result, combustion efficiency
directly influences the performance and operational
costs of production facilities. However, efficiency is not
the only concern. Compliance and safety are major
challenges as well.
Brief introduction to Fired Heaters operation and design. Definition of the different Heaters in the industry and brief strategy how to operate them safely.
Fired Heaters-Key to Efficient Operation of Refineries and PetrochemicalsAshutosh Garg
Fired Heaters are a critical to successful operation of refineries and petrochemical plants. They are a major energy consumer as well as a major source of air pollution. There are also concerns about the run length of the heaters as well safety issues.
Process Heaters, Furnaces and Fired Heaters: Improving Efficiency and Reducin...Belilove Company-Engineers
A process heater is a direct-fired heat exchanger that uses the hot gases of combustion to raise the temperature of a feed owing through coils of tubes aligned throughout the heater. Depending on the use, these are also called furnaces or red heaters. Some heaters simply deliver the feed at a predetermined temperature to the next stage of the reaction process; others perform reactions on the feed while it travels through the tubes.
Catalyst Catastrophes in Syngas Production - II
Contents
Review of incidents by reactor
Primary reforming
Secondary reforming
HTS
LTS
Methanator
Reactor loading
Support media
Some general comments on alternative actions when a plant gets into abnormal operation
New patented split flow technology increases the capacity of catalytic reformer heaters at a fraction of the cost of traditional revamps. Furnace Improvements has installed this technology in four reformer heaters at US refineries. This technology has also been used in several other heaters and one of the main benefits is lower pressure drop at increased capacity thus saving your pump or compressors.
.Coker heaters are one of the most critical heaters in the refineries. The feed is heated to a very high temperature. Run length is one of the important factors for coker heaters. We have worked recently worked on a conventional Coker heater and implemented several improvements while retubing the radiant section.
Air Preheat System Upgrade on Coker HeatersAshutosh Garg
Furnace Improvements design, engineered and revamped the existing air preheat system for a refinery in Houston. This paper was presented at an AIChE conference in October 2019.
Presentation made at the recent Refcomm Conference in Galveston, Texas about the improvements in a crude heater. The client started processing shale crudes and his run length came down to 3 months. FIS modified the heater and increased run length to almost 1.5 years. The project was completed last year. In this presentation, we are showing the CFD modeling of the heater before and after the modifications.
Burner Design, Operation and Maintenance on Ammonia PlantsGerard B. Hawkins
Burner Design, Operation and Maintenance on Ammonia Plants
Brief History
Reformer Burner Types/Design
Types of Reformers
Combustion Characteristics
Excess Air/Heater Efficiency
Maintenance, Good Practice
Low Nox Equipment
Summary
AIChE Smart Stack Damper Design Provides Better Control of Fired HeatersAshutosh Garg
Stack dampers are one of the insignificant yet important component of fired heaters in the refining industry. Over 90% of the heaters in the USA are natural draft and are dependent upon the draft for efficient combustion of fuel gas with air. Stack dampers currently installed are highly oversized and are not able to control draft effectively. Furnace Improvements patent pending design overcomes these limitations and improves the damper control significantly by installing multiple actuators and changing the control characteristics of the dampers.
Combustion sources such as furnaces and fired
heaters play a critical role in the process industry.
Unfortunately, combustion requires large amounts of
fuel (gas, fuel oil). As a result, combustion efficiency
directly influences the performance and operational
costs of production facilities. However, efficiency is not
the only concern. Compliance and safety are major
challenges as well.
Brief introduction to Fired Heaters operation and design. Definition of the different Heaters in the industry and brief strategy how to operate them safely.
Fired Heaters-Key to Efficient Operation of Refineries and PetrochemicalsAshutosh Garg
Fired Heaters are a critical to successful operation of refineries and petrochemical plants. They are a major energy consumer as well as a major source of air pollution. There are also concerns about the run length of the heaters as well safety issues.
Process Heaters, Furnaces and Fired Heaters: Improving Efficiency and Reducin...Belilove Company-Engineers
A process heater is a direct-fired heat exchanger that uses the hot gases of combustion to raise the temperature of a feed owing through coils of tubes aligned throughout the heater. Depending on the use, these are also called furnaces or red heaters. Some heaters simply deliver the feed at a predetermined temperature to the next stage of the reaction process; others perform reactions on the feed while it travels through the tubes.
Catalyst Catastrophes in Syngas Production - II
Contents
Review of incidents by reactor
Primary reforming
Secondary reforming
HTS
LTS
Methanator
Reactor loading
Support media
Some general comments on alternative actions when a plant gets into abnormal operation
A compact, fast responding electric heating element for clean gases in fuel cell, bio-med, laboratory, food, and pharmaceutical applications. The SuperCirc gas heater is designed for applications where fast heating of clean gases is required. All parts exposed to gas flow are constructed of 316SS (other materials available) rather than exposing process media to exposed resistance elements. This ensures that no foreign matter contaminates gas.
This presentation covers frequent and costly incidents related to catalysts mal-operation with the focus of providing the plant operator with recommendations to avoid plant outages and catalyst losses.
Purpose
Key to good performance
Problem Areas
Catalysts, heat shields and plant up-rates
Burner Guns
Development of High Intensity Ring Burner
Case Studies
Conclusions
Oil Cum gas Fired Boilers (Except Small size in Oil fired ) are three pass wet pack, horizontal, smoke tube type fusion welded. Boiler are made to IBR / DIN / BS / ASME code.Components are Engineered for maximum safety, Highest Efficiency, dependability and quite operation. Wet back Models eliminate rear end refractory and its inherent maintenance cost,reduces stress of rear tube sheet and ligament cracking, radiant heat is eliminated, lengthening tube life and reducing heat loss from rear turn around.
1. Fully wet - back design effectively absorbs radiant heat into the water, keeping tube ends and rear of coiler cooler than in dry back design.
2. Three passes extract maximum useble heat from the fuel.
3. Large water - surrounded furnace tube assures complete combustion and heat absorption without flame impingement.
CONSTRUCTION
ENERGYPACK Boilers are three pass wet back, horizontal, smoke tube type fusion welded. Boilers
are made to IBR/DIN/BS/ASME-code. Components are engineered for maximum safety, highest
efficiency, dependability and quiet operation. Wet back models eliminate rear end refractory and its
inherent maintenance cost, reduces stress of rear tube sheet and ligament cracking, radiant heat is
eliminated, lengthening tube life and reducing heat loss from rear turnaround.
Unique design features
♦ Fully automatic pressure jet Burner – Boiler furnace design suitable for Imported Weishaupt/Reillo & Indian modulating burner.
♦ Efficiency enhancement – Optional accessories such as air preheater and economizer can be integrated with the main unit.
♦ Automation with Programmable Logic Controllers (PLC) with Supervisory Control and Data Acquisition (SCADA) system can also be offered at an extra cost. Standard boilers are supplied with fully automatic operation with safety interlocks & alarm.
Oil Fired Boilers (Except Small size in Oil fired ) are three pass wet pack, horizontal, smoke tube type fusion welded. Boiler are made to IBR / DIN / BS / ASME code.Components are Engineered for maximum safety, Highest Efficiency, dependability and quite operation. Wet back Models eliminate rear end refractory and its inherent maintenance cost,reduces stress of rear tube sheet and ligament cracking, radiant heat is eliminated, lengthening tube life and reducing heat loss from rear turn around.
1. Fully wet - back design effectively absorbs radiant heat into the water, keeping tube ends and rear of coiler cooler than in dry back design.
2. Three passes extract maximum useble heat from the fuel.
3. Large water - surrounded furnace tube assures complete combustion and heat absorption without flame impingement.
CONSTRUCTION
ENERGYPACK Boilers are three pass wet back, horizontal, smoke tube type fusion welded. Boilers
are made to IBR/DIN/BS/ASME-code. Components are engineered for maximum safety, highest
efficiency, dependability and quiet operation. Wet back models eliminate rear end refractory and its
inherent maintenance cost, reduces stress of rear tube sheet and ligament cracking, radiant heat is
eliminated, lengthening tube life and reducing heat loss from rear turnaround.
Unique design features
♦ Fully automatic pressure jet Burner – Boiler furnace design suitable for Imported Weishaupt/Reillo & Indian modulating burner.
♦ Efficiency enhancement – Optional accessories such as air preheater and economizer can be integrated with the main unit.
♦ Automation with Programmable Logic Controllers (PLC) with Supervisory Control and Data Acquisition (SCADA) system can also be offered at an extra cost. Standard boilers are supplied with fully automatic operation with safety interlocks & alarm
We manufacturer from 100kg/hr to 14000 kg/hr
pressure up to- 35 kg/hr
DESIGN AND FABRICATION OF HELICAL TUBE IN COIL TYPE HEAT EXCHANGERhemantnehete
Heat exchangers are the important engineering systems with wide variety of applications including power plants, nuclear reactors, refrigeration and air-conditioning systems, heat recovery systems, chemical processing and food industries. Helical coil configuration is very effective for heat exchangers and chemical reactors because they can accommodate a large heat transfer area in a small space, with high heat transfer coefficients. This project focus on an increase in the effectiveness of a heat exchanger and analysis of various parameters that affect the effectiveness of a heat exchanger and also deals with the performance analysis of heat exchanger by varying various parameters like number of coils, flow rate and temperature. The results of the helical tube heat exchanger are compared with the straight tube heat exchanger in both parallel and counter flow by varying parameters like temperature, flow rate of cold water and number of turns of helical coil.
System Layout and Applications
Low Mass vs High Mass
Radiant Panels
Fan Coils
Domestic Hot Water
Solar Thermal
Balance Point Strategies
Heat Pump Application Software
Mono-Valent
Mono-Energetic
Bi-Valent
Programming for Energy Savings with User Interface
Affordable Stationery Printing Services in Jaipur | Navpack n PrintNavpack & Print
Looking for professional printing services in Jaipur? Navpack n Print offers high-quality and affordable stationery printing for all your business needs. Stand out with custom stationery designs and fast turnaround times. Contact us today for a quote!
RMD24 | Debunking the non-endemic revenue myth Marvin Vacquier Droop | First ...BBPMedia1
Marvin neemt je in deze presentatie mee in de voordelen van non-endemic advertising op retail media netwerken. Hij brengt ook de uitdagingen in beeld die de markt op dit moment heeft op het gebied van retail media voor niet-leveranciers.
Retail media wordt gezien als het nieuwe advertising-medium en ook mediabureaus richten massaal retail media-afdelingen op. Merken die niet in de betreffende winkel liggen staan ook nog niet in de rij om op de retail media netwerken te adverteren. Marvin belicht de uitdagingen die er zijn om echt aansluiting te vinden op die markt van non-endemic advertising.
Enterprise Excellence is Inclusive Excellence.pdfKaiNexus
Enterprise excellence and inclusive excellence are closely linked, and real-world challenges have shown that both are essential to the success of any organization. To achieve enterprise excellence, organizations must focus on improving their operations and processes while creating an inclusive environment that engages everyone. In this interactive session, the facilitator will highlight commonly established business practices and how they limit our ability to engage everyone every day. More importantly, though, participants will likely gain increased awareness of what we can do differently to maximize enterprise excellence through deliberate inclusion.
What is Enterprise Excellence?
Enterprise Excellence is a holistic approach that's aimed at achieving world-class performance across all aspects of the organization.
What might I learn?
A way to engage all in creating Inclusive Excellence. Lessons from the US military and their parallels to the story of Harry Potter. How belt systems and CI teams can destroy inclusive practices. How leadership language invites people to the party. There are three things leaders can do to engage everyone every day: maximizing psychological safety to create environments where folks learn, contribute, and challenge the status quo.
Who might benefit? Anyone and everyone leading folks from the shop floor to top floor.
Dr. William Harvey is a seasoned Operations Leader with extensive experience in chemical processing, manufacturing, and operations management. At Michelman, he currently oversees multiple sites, leading teams in strategic planning and coaching/practicing continuous improvement. William is set to start his eighth year of teaching at the University of Cincinnati where he teaches marketing, finance, and management. William holds various certifications in change management, quality, leadership, operational excellence, team building, and DiSC, among others.
The world of search engine optimization (SEO) is buzzing with discussions after Google confirmed that around 2,500 leaked internal documents related to its Search feature are indeed authentic. The revelation has sparked significant concerns within the SEO community. The leaked documents were initially reported by SEO experts Rand Fishkin and Mike King, igniting widespread analysis and discourse. For More Info:- https://news.arihantwebtech.com/search-disrupted-googles-leaked-documents-rock-the-seo-world/
Implicitly or explicitly all competing businesses employ a strategy to select a mix
of marketing resources. Formulating such competitive strategies fundamentally
involves recognizing relationships between elements of the marketing mix (e.g.,
price and product quality), as well as assessing competitive and market conditions
(i.e., industry structure in the language of economics).
Digital Transformation and IT Strategy Toolkit and TemplatesAurelien Domont, MBA
This Digital Transformation and IT Strategy Toolkit was created by ex-McKinsey, Deloitte and BCG Management Consultants, after more than 5,000 hours of work. It is considered the world's best & most comprehensive Digital Transformation and IT Strategy Toolkit. It includes all the Frameworks, Best Practices & Templates required to successfully undertake the Digital Transformation of your organization and define a robust IT Strategy.
Editable Toolkit to help you reuse our content: 700 Powerpoint slides | 35 Excel sheets | 84 minutes of Video training
This PowerPoint presentation is only a small preview of our Toolkits. For more details, visit www.domontconsulting.com
"𝑩𝑬𝑮𝑼𝑵 𝑾𝑰𝑻𝑯 𝑻𝑱 𝑰𝑺 𝑯𝑨𝑳𝑭 𝑫𝑶𝑵𝑬"
𝐓𝐉 𝐂𝐨𝐦𝐬 (𝐓𝐉 𝐂𝐨𝐦𝐦𝐮𝐧𝐢𝐜𝐚𝐭𝐢𝐨𝐧𝐬) is a professional event agency that includes experts in the event-organizing market in Vietnam, Korea, and ASEAN countries. We provide unlimited types of events from Music concerts, Fan meetings, and Culture festivals to Corporate events, Internal company events, Golf tournaments, MICE events, and Exhibitions.
𝐓𝐉 𝐂𝐨𝐦𝐬 provides unlimited package services including such as Event organizing, Event planning, Event production, Manpower, PR marketing, Design 2D/3D, VIP protocols, Interpreter agency, etc.
Sports events - Golf competitions/billiards competitions/company sports events: dynamic and challenging
⭐ 𝐅𝐞𝐚𝐭𝐮𝐫𝐞𝐝 𝐩𝐫𝐨𝐣𝐞𝐜𝐭𝐬:
➢ 2024 BAEKHYUN [Lonsdaleite] IN HO CHI MINH
➢ SUPER JUNIOR-L.S.S. THE SHOW : Th3ee Guys in HO CHI MINH
➢FreenBecky 1st Fan Meeting in Vietnam
➢CHILDREN ART EXHIBITION 2024: BEYOND BARRIERS
➢ WOW K-Music Festival 2023
➢ Winner [CROSS] Tour in HCM
➢ Super Show 9 in HCM with Super Junior
➢ HCMC - Gyeongsangbuk-do Culture and Tourism Festival
➢ Korean Vietnam Partnership - Fair with LG
➢ Korean President visits Samsung Electronics R&D Center
➢ Vietnam Food Expo with Lotte Wellfood
"𝐄𝐯𝐞𝐫𝐲 𝐞𝐯𝐞𝐧𝐭 𝐢𝐬 𝐚 𝐬𝐭𝐨𝐫𝐲, 𝐚 𝐬𝐩𝐞𝐜𝐢𝐚𝐥 𝐣𝐨𝐮𝐫𝐧𝐞𝐲. 𝐖𝐞 𝐚𝐥𝐰𝐚𝐲𝐬 𝐛𝐞𝐥𝐢𝐞𝐯𝐞 𝐭𝐡𝐚𝐭 𝐬𝐡𝐨𝐫𝐭𝐥𝐲 𝐲𝐨𝐮 𝐰𝐢𝐥𝐥 𝐛𝐞 𝐚 𝐩𝐚𝐫𝐭 𝐨𝐟 𝐨𝐮𝐫 𝐬𝐭𝐨𝐫𝐢𝐞𝐬."
Memorandum Of Association Constitution of Company.pptseri bangash
www.seribangash.com
A Memorandum of Association (MOA) is a legal document that outlines the fundamental principles and objectives upon which a company operates. It serves as the company's charter or constitution and defines the scope of its activities. Here's a detailed note on the MOA:
Contents of Memorandum of Association:
Name Clause: This clause states the name of the company, which should end with words like "Limited" or "Ltd." for a public limited company and "Private Limited" or "Pvt. Ltd." for a private limited company.
https://seribangash.com/article-of-association-is-legal-doc-of-company/
Registered Office Clause: It specifies the location where the company's registered office is situated. This office is where all official communications and notices are sent.
Objective Clause: This clause delineates the main objectives for which the company is formed. It's important to define these objectives clearly, as the company cannot undertake activities beyond those mentioned in this clause.
www.seribangash.com
Liability Clause: It outlines the extent of liability of the company's members. In the case of companies limited by shares, the liability of members is limited to the amount unpaid on their shares. For companies limited by guarantee, members' liability is limited to the amount they undertake to contribute if the company is wound up.
https://seribangash.com/promotors-is-person-conceived-formation-company/
Capital Clause: This clause specifies the authorized capital of the company, i.e., the maximum amount of share capital the company is authorized to issue. It also mentions the division of this capital into shares and their respective nominal value.
Association Clause: It simply states that the subscribers wish to form a company and agree to become members of it, in accordance with the terms of the MOA.
Importance of Memorandum of Association:
Legal Requirement: The MOA is a legal requirement for the formation of a company. It must be filed with the Registrar of Companies during the incorporation process.
Constitutional Document: It serves as the company's constitutional document, defining its scope, powers, and limitations.
Protection of Members: It protects the interests of the company's members by clearly defining the objectives and limiting their liability.
External Communication: It provides clarity to external parties, such as investors, creditors, and regulatory authorities, regarding the company's objectives and powers.
https://seribangash.com/difference-public-and-private-company-law/
Binding Authority: The company and its members are bound by the provisions of the MOA. Any action taken beyond its scope may be considered ultra vires (beyond the powers) of the company and therefore void.
Amendment of MOA:
While the MOA lays down the company's fundamental principles, it is not entirely immutable. It can be amended, but only under specific circumstances and in compliance with legal procedures. Amendments typically require shareholder
Falcon stands out as a top-tier P2P Invoice Discounting platform in India, bridging esteemed blue-chip companies and eager investors. Our goal is to transform the investment landscape in India by establishing a comprehensive destination for borrowers and investors with diverse profiles and needs, all while minimizing risk. What sets Falcon apart is the elimination of intermediaries such as commercial banks and depository institutions, allowing investors to enjoy higher yields.
[Note: This is a partial preview. To download this presentation, visit:
https://www.oeconsulting.com.sg/training-presentations]
Sustainability has become an increasingly critical topic as the world recognizes the need to protect our planet and its resources for future generations. Sustainability means meeting our current needs without compromising the ability of future generations to meet theirs. It involves long-term planning and consideration of the consequences of our actions. The goal is to create strategies that ensure the long-term viability of People, Planet, and Profit.
Leading companies such as Nike, Toyota, and Siemens are prioritizing sustainable innovation in their business models, setting an example for others to follow. In this Sustainability training presentation, you will learn key concepts, principles, and practices of sustainability applicable across industries. This training aims to create awareness and educate employees, senior executives, consultants, and other key stakeholders, including investors, policymakers, and supply chain partners, on the importance and implementation of sustainability.
LEARNING OBJECTIVES
1. Develop a comprehensive understanding of the fundamental principles and concepts that form the foundation of sustainability within corporate environments.
2. Explore the sustainability implementation model, focusing on effective measures and reporting strategies to track and communicate sustainability efforts.
3. Identify and define best practices and critical success factors essential for achieving sustainability goals within organizations.
CONTENTS
1. Introduction and Key Concepts of Sustainability
2. Principles and Practices of Sustainability
3. Measures and Reporting in Sustainability
4. Sustainability Implementation & Best Practices
To download the complete presentation, visit: https://www.oeconsulting.com.sg/training-presentations
Sustainability: Balancing the Environment, Equity & Economy
FIS Case Studies- Executed Projects Only
1. Furnace Improvements Services
Low Cost Value Added Solutions for Fired Heaters
Project Case Studies
Increased Capacity Higher Efficiency
Longer Run Lengths Lower NOx Emissions
Furnace Improvements Services Inc. A.G. Furnace Improvements Pvt. Ltd.
1600 Highway 6, Suite 480 K-33, Kalkaji
Sugar Land, TX 77478 New Delhi – 110019
Tel: (281)980-0325 Tel 1: 91-11-405 8 8696
Fax: (832) 886-1665 Tel 2: 91-11-262-8 6775
Email: info@heatflux.com
Web: www.heatflux.com
Case Study 183
2. Furnace Improvements
Low Cost Solutions for Fired Heaters
No. 4 Platformer Heater Capacity
Improvement
In October 2000, FIS carried out a Platformer Heater Revamp Project for a refinery in Corpus
Christi, TX.
The four-cell Reformer Heater was originally designed for a heat duty of 181.32 MMBtu/hr, in
1970. The heater was operating at 67% thermal efficiency. Client wanted to increase the capacity
and improve the efficiency of this heater but didn’t want an air preheater system and neither
generates steam.
The refinery approached the original designer of the heater. They proposed a conventional
scheme to preheat the feed in the convection section. The scheme had four major drawbacks:
• Increased of fluid pressure drop
• Required grade mounted stack
• Required large diameter piping
• Cost was very high
FIS was contacted by the refinery to
develop an economical scheme for
improving efficiency. FIS redesigned
the heater with our patented “Split
Flow Technology” scheme. In this
scheme the feed is heated parallel in
the convection and radiant sections.
This design works very well to
increase capacity and minimizing the
pressure drop during the process.
FIS scheme was able to increase capacity, FIS Split Flow* Technology applied to Platform Heater
and improve efficiency with the following
advantages:
• Fluid pressure drop decreases
• Existing stacks were reused.
• Additional piping was only half the size of conventional scheme.
• Scheme was nearly half the cost of conventional revamp.
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3. Furnace Improvements
Low Cost Solutions for Fired Heaters
FIS carried out the entire
scope of activities from Reformer Heater Data Comparison
conceptualization to Before Revamp
Item Units After Revamp
commissioning of this (Operating)
heater revamp. The heater Capacity BPD 18,000 26,000
was successfully
commissioned in October Heat Release MM Btu/hr 234 225
2002. After revamp, the Stack Temp. °F 1,092 478
capacity of this heater was
improved from 18,000 BPD Fuel MSCFH 244 242.8
Consumption
to 26,000 BPD. The client is
5.8 Million *
very pleased with the heater Fuel Savings $/annum
* Based on $6.0 / MMBtu
performance. The heater has
been running successfully since 2002.
Reformer Heater Before and After Revamp
*Split Flow Patented Technology – US 7204 966B2
Client CITGO
Client Contact Mr. Ed De La Cruz
Telephone (361) 844-5741
Location Corpus Christi, TX
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4. Furnace Improvements
Low Cost Solutions for Fired Heaters
•••
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5. Furnace Improvements
Low Cost Solutions for Fired Heaters
Case Study 185
CFHT Efficiency Improvement and
NOx Reduction Project
A northern refinery had a Catalytic Feed Hydrotreater Heater (CFHT) in their Fluid Catalytic
Cracking (FCC) unit. It is a natural draft vertical cylindrical furnace, with a horizontal overhead
convection section and three up fired low NOx natural draft burners. Client was having tube
failures in this heater and decided to contact Furnace Improvements (FIS). They also wanted to
replace the burners.
Furnace Improvements carried out a thorough analysis of the heater. The existing convection
section was designed with very tight design parameters. It also had a very high heat flux leading
to high skin temperatures and subsequent tube failures. The burners had a very high heat release
rate, and were leading to long flames and flame impingement.
FIS redesigned the convection section within one week with a better design overcoming the
drawbacks in the existing design. FIS also replaced the existing burners with six new low NOx
burners and re-rate the heater. FIS developed the detail engineering and fabrication drawings for
the convection section and burners replacement. FIS also developed material and burner
specifications, evaluated the vendor quotations, and witnessed the burner test.
CFHT Heater Parameters
Before After
Parameter Units
Revamp Revamp
Heat Duty MMBtu/hr 16.70 16.70
Heat Release MMBtu/hr 21.64 19.45
Skin Temp. °F 740 675
Efficiency % 79.57 85.87
Stack Temp. °F 764 537
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6. Furnace Improvements
Low Cost Solutions for Fired Heaters
After the revamp job, the performance of the heater improved as expected. The some of the
results were:
• Radiant section skin temperature was reduced from 740°F to 675°F.
• Thermal efficiency was improved from 79.5% to 86%.
• Stack flue gas temperature was reduced from 764°F to 537°F.
The heater was successfully commissioned in October 2003.
Client ConocoPhillips
Client Contact Mr. Hiren Yagnik
Telephone (618) 255-2534
Location Roxana, IL
•••
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7. Furnace Improvements
Low Cost Solutions for Fired Heaters
Case Study 187
Reboiler Trim Heaters Efficiency
Improvement Project
There were two trim heaters, stripper and stabilizer reboiler, in STABILIZER REBOILER HEATER
a reforming plant. Convection Section
#1 #2
The heaters were originally designed for a heat duty of 12 and
13.8 MM Btu/hr respectively. The convection sections in these
heaters were in poor condition. They were operating at very #1 #2
low efficiency. Client contacted Furnace Improvements (FIS) 12'- 5"
looking to improve the performance of these trim heaters.
9'- 8"
FIS studied the design and operating conditions of the heaters.
FIS solution was to replace the existing convection sections #1 #2 #1 #2
and provide new stacks to increase the capacity of the heaters 5'- 3 1/4"
Convection Section
5'- 3 1/4"
Convection Section
Before and After Revamp
(Before Revamp)
(After Revamp)
by 10% and improve their thermal efficiency by 7-8%.
Trim Heaters Parameters (Stripper / Stabilizer)
Before After Before After
Parameter Units Parameter Units
Revamp Revamp Revamp Revamp
MMBtu/ MMBtu/
Heat Duty 13.78 15.14 Heat Duty 12.0 13.20
hr hr
Heat MMBtu/ Heat MMBtu/
18.06 18.29 16.13 16.10
Release hr Release hr
Efficiency % 76.4 83.2 Efficiency % 74.4 82.0
Stack Stack
°F 813 572 °F 832 575
Temp. Temp.
FIS carried out process design, detailed engineering, fabrication drawings, engineering
specifications, material requisitions, and supervised field activities. The heaters are running with
the enhanced capacity and efficiency since October 2002.
Client CITGO
Client Contact Mr. Ed De La Cruz
Telephone (361) 844-5741
Location Corpus Christi, TX •••
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8. Furnace Improvements
Low Cost Solutions for Fired Heaters
Case Study 204
Crude Furnace NOx Reduction and Capacity
Increase Project
An Ohio refinery has a Crude Heater in their Crude
Unit. The Crude Heater is a balanced draft, box type,
horizontal tube radiant heater, having a common
convection section on top. The heater was originally
built in 1968 for 423.2 MMBtu/hr heat duty. The
convection section is designed to preheat oil feed
and also super heat steam from 371°F to 450°F.
This furnace had 84 up-fired burners having a total
heat release of about 500 MMBtu/hr.
Client contacted Furnace Improvements (FIS) to
perform an engineering study for NOx reduction on
this furnace and modeled the furnace with Ultra
Low NOx Burners.
During the study it was found that the radiant tubes
in this heater had been suffering from high tube
metal temperature and flame impingement. The
convection section was inefficient; the air preheater
operating temperature was reaching their
metallurgical limits and the flue gas temperature
leaving the convection section was 300°F higher than
design.
Furnace Improvements modified the convection section and reduced relative coking rates. The
relative coking rates in the existing convection section and the proposed retubed convection
section are shown in the graph below. The Client accepted our recommendations and
immediately assigned FIS the NOx reduction and performance improvement project.
FIS Revamp consists of:
• Modifying the radiant section
• Retubing the convection section
• Burners replacement with Ultra Low NOx burners
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9. Furnace Improvements
Low Cost Solutions for Fired Heaters
Relative Coking Rates in Convection Section
0.3
0.25
Relative Coking Rate
0.2
Existing
0.15
Proposed
0.1
0.05
0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Tube No.
FIS developed the detailed engineering and fabrication drawings for this revamp. We also
developed the detailed specifications for tubes, finning, tube supports, burners, burner supports,
fabrication and erection. We floated enquires, evaluated vendor proposals, and made
recommendations for placing a direct purchase order to the vendors. We carried out testing on
the burners and checked the parameters while the heater was running with full capacity.
Parameters Units Pre Revamp Post Revamp
Capacity BPD 155,900 160,000
Heater Duty (Process + Steam) MMBtu/hr 443.1 450.46
Maximum TMT (rad. /conv.) °F 996 / 1,130 801 / 746
The client is able to process more throughput than expected. The tube skin temperatures are very
low. The NOx emissions were reduced to ≈ 0.05 lb/MMBtu. The heater was commissioned in
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10. Furnace Improvements
Low Cost Solutions for Fired Heaters
April 2004 and has been running successfully ever since.
Client Premcor
Client Contact Mr. Jim Prorok
Telephone (419) 226 2610
Location Lima, OH
•••
Case Study 210
No.2 Reformer Heater NOx Reduction
Project
A Reformer Heater was designed as a multi-cell heater consisting of five radiant cells, a common
convection section and five stacks. The heater was originally designed for 12,000 BPD charge
rate. It was revamped several times. The existing heater is rated to process 24,000 BPD of feed
(Naphtha) at an absorbed heat duty of 160.6 MM Btu/hr, an efficiency of 86.9% with a total of 62
burners.
Furnace Improvements (FIS) was
approached to do the study and develop
options to reduce NOx emissions.
FIS reviewed the design and operating data
and recommended replacing the existing
burners with Next Generation Ultra Low
NOx Burners.
Two of the cells have staged fuel burners and
other three-cells have premix burners. The
four cells (A, B, C, & D) have 14 burners
each and the last cell (E) has only 6 burners.
FIS installed 15 burners in cells A, B, C, &
D. The burners were installed on a staggered pattern to allow maximum flue gas recirculation.
Cell E, have the same number of burners as existing.
FIS carried out the entire scope of activities from conceptualization to commissioning of this
heater revamp. The heater was successfully commissioned in October 2004. The NOx emissions
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11. Furnace Improvements
Low Cost Solutions for Fired Heaters
were reduced to less than 0.03 lbs Btu.
Client ConocoPhillips
Client Contact Mr. Brent Colle
Telephone (580) 767 2499
Location Ponca City, OK
•••
Case Study 242
NHT and Platformer Heater Capacity
Increase Project
The Platformer Heater (H-20/21/22) was originally
designed for 12,000 BPD operation and rated for 119.6
MMBtu/hr process heat duty. The design thermal
efficiency of the heater was ~ 88% but it was operating
only at 80 – 81%.
There are three vertical Cylindrical Heaters along with
the Platformer Heaters, which share a common
convection section and a stack. They are the
Hydrotreater Charge Heater (H-18), Hydrotreater
Stripper Reboiler (H-19) and Depropaniser Reboiler
(H-23).
The heaters were running at 13,000 to 15,000 BPD charge rate. Client wished to revamp the
heaters to 18,000 BPD capacity. Furnace Improvements (FIS) was employed to develop the best
capacity improvement scheme for a #2 Platformer Heater and NHT Heaters.
The conventional revamp option was to extend the existing radiant cells. The other option was to
install a new heater for extra duty required. Both options require a big amount of space and high
cost.
Heater Existing Heat Revamped Extra
Duty Duty Duty
FIS’ recommendation was to increase the
H-18 11.97 13.50 1.53
capacity of the heater based on FIS patented
H-19 18.45 23.50 5.05
“Split Flow Technology”. The heaters were
H-20 27.29 42.50 15.21
Revamping - TrainingH-21
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25.10 30.90 5.30
H-22
www.heatflux.com 21.70 23.10 1.40
H-23 15.15 17.40 2.25
Total 119.7 150.90 30.74
12. Furnace Improvements
Low Cost Solutions for Fired Heaters
revamped for 18,000 BPD capacity and a design heat duty of 150.4 MMBtu/hr. The revamp cost
was one fourth of the alternate design. The heater firing was limited to the design firing rate. The
thermal efficiency of the heaters was increased from 80% to 89%.
FIS Revamp consists of:
• Replacement of Coils
• New Burners and Radiant Floor
• New Convection Section
• Replacement of Stack Damper
The heater was revamped not only for increased capacity but also for improved thermal
efficiency and improved reliability. In addition to this, the Platformer Heater’s burners were
replaced with new Ultra Low NOx flat flame burners and the calculated fuel consumption
savings are $876,700 per year.
Before Revamp After Revamp
FIS carried out the entire scope of activities from conceptualization to commissioning of this
heater revamp. The heater was successfully commissioned in November 2005 and has been
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13. Furnace Improvements
Low Cost Solutions for Fired Heaters
running ever since.
Client Valero
Client Contact Mr. Steven Guillory
Telephone (409) 948-7463
Location Texas City, TX
•••
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14. Furnace Improvements
Low Cost Solutions for Fired Heaters
Case Study 247
Combined Feed Heater
The first new heater job by Furnace Improvements (FIS) was
for a Corpus Christi refinery. The new vertical cylindrical
heater is a combined feed heater with a natural draft. It is used
to heat a mixture of hydrocarbon and hydrogen.
The heater was designed for:
• Absorbed heat duty - 40MMBtu/hr
• Feed Flow Rate – 450,995 lb/hr
• 6 Ultra Low NOx Burners
• Efficiency - 82%
FIS’ scope of services for this heater included design,
engineering, fabrication, procurement, supply and project
services.
The heater was successfully commissioned in August 2005.
Client CITGO
Client Contact Mr. Ed De La Cruz
Telephone (361) 844-5741
Location Corpus Christi, TX
•••
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15. Furnace Improvements
Low Cost Solutions for Fired Heaters
Case Study 248
Platformer Heater Capacity Improvement
Project
Furnace Improvements (FIS) was employed by a
refinery in California to perform a capacity
improvement on a Platformer Heater (H-70-01/02/03).
The heater was originally built in 1979. It was designed
for 12 MBPD and rated for 135.58 MMBtu/hr of heat
duty and 84.03 MMBtu/hr of process heat duty. The
heater was running at 13,000 to 15,000 BPD charge
rate.
Client was seeking to revamp the heater for 18,000
BPD and process heat duty of 113.01 MMBtu/hr and
total heat duty of 160.86 MMBtu/hr.
The design thermal efficiency of the heater was ~ 88%
and was operating at 80- 81%. The stack temperature
was higher by almost 300°F than design.
The conventional revamp option was to extend the existing radiant cells. Extending the radiant
cells has the following disadvantages:
• Space limitation
• Higher firing rates
• Very high cost ( requires radiant tubes and new manifolds)
FIS’ recommended increasing the capacity of the heater using our patented “Split Flow
Technology”. Advantages of revamped design based on split flow are as follows:
• Lower heat flux
• Lower firing rates
• No radiant section modification
• No civil works
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16. Furnace Improvements
Low Cost Solutions for Fired Heaters
Design Revamp Extra Duty Re-Rated Convection
Heater
Heat Duty Heat Duty Required Radiant Duty Duty
Section
MMBtu/hr
70-H-1 27.68 37.47 9.79 29.01 8.46
70-H-2 33.42 44.66 11.24 34.45 10.21
70-H-3 22.93 30.88 7.95 24.35 6.53
Steam
51.58 47.85 - - 47.85
Generation
Total
Process 84.03 113.01 28.08 87.81 25.2
Duty
The overall heater efficiency was improved 9%. There was an increased heat duty by 28.08
MMBtu/hr, about 33% more than the original design values. The firing rate was well within the
original firing rate.
FIS carried out the entire scope of activities from conceptualization to commissioning of this
heater revamp. The heater was successfully commissioned in February 2008.
Client Valero
Client Contact Mr. Pat Leyel
Telephone (562) - 491-7256
Location Wilmington, CA
•••
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17. Furnace Improvements
Low Cost Solutions for Fired Heaters
Case Study 254
Crude Heater NOx Reduction Project
A refinery has a Crude Heater (191-H-1) in its Atmospheric Vacuum Unit AVU-191. The heater
was built in 1969 and designed for 160,000 BPD at a total heat duty of 490.7 MMBtu/hr. The
heater was later revamped to process 178,500 BPD of crude and 31,500 BPD of slip stream at
total heat duty of 612.4 MMBtu/hr.
Furnace Improvements (FIS) was
approached to modify the existing Crude
Heater (191-H-1) to enable it to be retrofitted
with a selective Catalytic Reduction Unit
(SCR) to reduce NOx emissions to less than
0.010 lb/MMBtu. A new SCR and Waste
Heat Recovery (WHR) are installed to
accomplish these changes. FIS also
performed the CFD analysis to ensure there is
proper mixing of Ammonia with flue gases in
the SCR unit and there is uniform distribution of
flue gases over the catalyst bed.
In the proposed option FIS designed the
heater for 260,000 BPD at a firing rate of 727
MMBtu/hr (LHV). Crude feed to 191-H-1 is split into two streams: A hot stream (main crude
charge) at 215,000 BPD, 456° F and a cold stream (slip crude stream) at 45,000 BPD, 240° F.
The total absorbed heat duty of the Crude Heater is 672.2 MMBtu/hr. The WHR section is
designed to reduce the flue gas temperature to 300° F as opposed to the current 350° F to 385° F.
FIS’ scope included providing engineering services, designing equipment and supplying
materials needed to modify the existing Crude Heater and auxiliary equipments. FIS’ scope
included the supply of a new waste heat recovery unit, modify the existing heater convection,
and upgrade of the FD and ID Fans. The new waste heat recovery is installed and connected to
the new SCR and existing Crude Heater.
Crude Heater Revamp
The existing slip crude stream in the convection section has 24 rows. Fourteen rows are removed
from service to achieve the required temperature window for SCR operation. The convection
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18. Furnace Improvements
Low Cost Solutions for Fired Heaters
section is divided into two sections: lower and upper, by installing a new horizontal baffle plate.
The plate acts as a barrier and forces the flue gases to exit from the lower section to the SCR,
WHR and return to the upper section. The blanking plate is a new concept and it’s being done for
the 1st time. This design saved our client between $5- $6 Million.
Waste Heat Recovery Unit
The Crude Heater (191-H-1) is supplemented with an outboard WHR unit. The unit is located
downstream of the SCR unit. The heat transfer area was removed from the heater convection
section to achieve the required temperature window. This was done to avoid condensation
recovered in the WHR. The design slip crude flow rate through the WHR will be 45,000 BPD
(560,000 lb/hr). The outboard WHR unit will heat slip crude stream from 240° F to 470° F. The
calculated pressure drop across the WHR is 46.9 psig. The flue gas enters the WHR at a
temperature of 700° F and leaves at 300° F.
Soot Blowers
Twenty-eight electric-motor driven soot blowers are provided in the WHR unit. The soot blowers
are installed in the WHR to clean the surfaces for any ammonium bisulphate deposits resulting
from the reaction of excess NH3 and SO3.
FD & ID Fans
The FD fans are upgraded to increase capacity and reduce the noise across the combustion
systems. The fans are retrofitted with a new impeller, shaft, inlet vanes, inlet cones to match new
rotor, inlet damper and silencer and intake hood. The motor is also being upgraded from a 400
HP to 500 HP motor. Similarly the four ID fans and motors are upgraded.
Dampers
There are a total of 16 dampers being provided in the Crude Heater. All the 16 dampers are
replaced because they were not in working condition. The new dampers are installed at the
existing damper locations.
Finger Ducts & Expansion Joints
New duct work is installed to the north side of the Crude Heater. The hot flue gas ducting is
designed to optimally fit from the heater to the new SCR and also from SCR to WHR. The hot
flue gas enters the duct, passes through the Ammonia Injection Grid (AIG) and enters the SCR.
Expansion joints were also provided on each duct. Cold flue gas ducting was designed to fully
integrate with the WHR system with the existing convection box (below the existing ID fans).
The six cold flue gas ducts tie into heater above the blanking plate.
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19. Furnace Improvements
Low Cost Solutions for Fired Heaters
Ammonia Injection Grid
The new AIG was installed in the hot flue gas finger ducts. The AIG is located 10 ft from the
heater casing. Ammonia is injected from the bottom through these pipes in the direction of the
flue gas flow. NOx in the flue gases reacts with Ammonia over a catalyst to form Nitrogen and
water vapor.
Description Before Revamp After Revamp
Total Heat Duty, MMbtu/Hr 612.4 672.2
Heater Efficiency (LHV), % 91 92.4
Stack Temperature, °F 350 – 385 300
NOx, lb/MMbtu < 0.01 lb/MMBtu
The total cost of the project for design, engineering, fabrication and supply was $7 Million.
Erection has been completed and the heater was commissioned in February 2009.
Client ConocoPhillips
Client Contact Mr. David Burkholder
Telephone 504-656-3427
Location Belle Chasse, LA
•••
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20. Furnace Improvements
Low Cost Solutions for Fired Heaters
Case Study 255
Reactor Charge Heater (B-301) Capacity
Increase Project
A Port Arthur Refinery has a reactor charge heater in the GFU Unit. The charge heater is a
vertical cylindrical heater built in 1981 with an air preheating system. It was designed for a total
heat duty of 60 MM Btu/hr.
Furnace Improvements (FIS) was employed in March 2005 to rerate the heater. The rerating was
to be done with new process conditions to minimize the pressure drop.
FIS rerated the heater for new process conditions
using our patented “Split Flow Technology”. FIS
also utilized the convectional series flow technology
to minimize the pressure drop and hardware changes,
therefore, overall minimizing project cost.
FIS recommended rearrangement of the number of
passes or the replacement of the radiant and
convection sections.
FIS carried out the entire scope of activities from
conceptualization to commissioning of this heater
revamp. The heater was successfully revamped in
December 2006 and restarted operation in January
2007. The client is very pleased with the heater
performance.
Before Revamp
Client Valero
Client Contact Mr. Steve Henderson
Telephone (409) 985-1135
Location Port Arthur, TX
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21. Furnace Improvements
Low Cost Solutions for Fired Heaters
•••
Case Study 260
Capacity Improvement for Reactor Charge
Heater (080-H-001)
Furnace Improvements (FIS) was employed to carry out a capacity improvement of the Reactor
Charge Heater (080-H-001). The client wanted to increase the process heat duty from 29.95
MMBtu/hr to 37 MMBtu/hr. The maximum firing rate limitation was 54 MMBtu/hr.
This heater was originally built in 1965 as a
natural draft all radiant heater. It was modified
in 1980 to increase its thermal efficiency from
55% to 89% by adding a convection section for
steam generation. The heater was operating at
85% efficiency.
The revamp options to increase the capacity of
the heater were:
• Replace existing radiant coil and put in a
new convection to preheat the process feed.
• Revamp using FIS Split Flow Technology.
In this option, the process feed is split and
heated parallel in radiant and convections
sections. The two parallel streams are then
combined at the outlet.
FIS revamped the heater, for increasing the processing capacity, using “Split Flow Technology.”
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22. Furnace Improvements
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Parameter Units Design Operating Revamp
Total Absorbed Duty MMBtu/hr 47.63 55.48 42.4
Process Duty (Total) MMBtu/hr 29.99 37.68 37.01
Process Radiant Duty MMBtu/hr 29.99 37.68 25.01
Process Convection Duty MMBtu/hr - - 12
Total Fuel Firing Rate MMBtu/hr 53.47 64.83 49.87
Firebox Temperature °F 1540 1630 1511
Radiant Average Heat
Btu/hr/ft2 11,820 14,850 11,480
Flux
Advantages of the revamped design based on Split Flow are as follows:
a) No radiant section modification – Existing tubes and supports can be used
b) Steam generation system can be reused with minimum modifications
c) Lowest cost
d) Shortest turn-around time
The heater is operating successfully after revamp. FIS carried out the entire scope of activities
from conceptualization to commissioning of this heater revamp.
Client Alon USA
Client Contact Mr. Steve Mattingley / Mr. Jeff Broman
Telephone (432) 263-9333/ (432) 263-9237
Location Big Spring, TX
•••
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23. Furnace Improvements
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Case Study 263B
N 744 Boiler NOx
Reduction Project
Furnace Improvements (FIS) was approached
to convert a CO boiler in Unit 40 to be a
standalone refinery fuel gas fired boiler, and
reduce NOx emissions. The existing boiler
was revamped into a fuel gas fired boiler with
a maximum capacity of 400,000 lb/hr of
steam @ 625 psig, 750 °F and reduced the
NOx emissions down to 0.02 lb/MMBTU (16
ppm).
FIS developed a heat transfer model of the boiler. Analyzed the performance of the boiler with
NOx reduction and provided the client with various options for NOx reduction. They selected the
option of ultra low NOx burners with external flue gas recirculation and steam injection into the
burners. FIS scope of services included the following:
• NOx Reduction System - Ultra Low NOx Burners and FGR Fan:
The burners required about 16-17% FGR and 20,000 Lbs/Hr steam injection to reduce the
NOx emissions to 0.02 Lb/MMBtu. FIS procured the FGR fan. FIS performed the CFD
modeling of the ducting and combustion air – FGR mixbox to ensure that FGR and
combustion air are thoroughly mixed before it enters the burners. FIS also performed the
CFD modeling of the existing and new ultra low NOx burners to predict the overall
combustion scenario, flame patterns, flame lengths etc.
• New Economizer:
The existing economizer was heavily fouled and the stack temperatures were running
about 460 °F. FIS installed a new economizer which increased the efficiency of the boiler
by 3%. The additional fuel savings due to increased efficiency will pay out the new
economizer in about one year and six months. The lower stack temperature (310 °F) with
the new economizer also reduced the size of the FGR fan.
• Steam Super Heater Modifications:
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24. Furnace Improvements
Low Cost Solutions for Fired Heaters
FIS performed the heat transfer modeling of the steam super heater and found that the
existing heat transfer surface was inadequate and steam temperature will drop to about
680 °F after the revamp. FIS put additional heat transfer surface in the super heater to
raise the temperature to 810 °F.
• Firebox Modifications:
FIS maximized the heat transfer surface in the firebox by sealing the CO ports with water
wall panels, and removing the refractory from the floor and the roof. The additional heat
transfer surface in the firebox increases the radiant heat duty and lowers the firebox
temperature that also helps in reducing NOx to a little extent.
• New Attemperator:
The existing attemperator was not working. FIS installed a new attemperator to maintain
a constant super heat temperature at all boiler loads.
Description Before Revamp After Revamp
Stack Temperature 460 °F 310 °F
Boiler Efficiency (LHV) 87% 90 %
Steam Temperature Out Of Boiler 700 – 730 °F 730 – 810 °F
Steam Temperature after Not Working 730 - 750 °F
Attemperator
NOx < 0.02 Lb/MMBtu (HHV)
This project was on a fast track. Engineering and procurement of all materials was completed in
10 months. The boiler was successfully commissioned in April 2008.
Client ConocoPhillips
Client Contact Mr. Steven J. O'Donnell
Telephone (806) 275-1307
Location Borger, TX
•••
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25. Furnace Improvements
Low Cost Solutions for Fired Heaters
Case Study 266
Alky Heater (H-2) NOx Reduction and
Efficiency Improvement Project
Furnace Improvements (FIS) was hired to perform a
turnkey NOx Reduction revamp on an Alky Unit
Heater (H-2). The target NOx emission rate was
0.035 lb/MMBtu (HHV). The Alky Heater is a
vertical cylindrical heater with a design heat duty of
55 MMBtu/hr. The heater efficiency was very low
at 66%.
Excess Oxygen in the firebox was very high at
8.5%. The heater floor was in bad shape. The heater
did not have any stack damper for draft control.
FIS’ scope included finalization of thermal design
and engineering, procurement of material,
fabrication, supply and field installation of the
heater.
FIS scope of services included:
• Modification of Existing Floor:
The existing floor was in bad shape, warped and needed to be replaced. The burners were
fitted on smaller burner circle diameter to increase the reliability of the heater by minimizing
the flame impingement.
• Install Eight New Ultra Low NOx Burners (ULNB):
FIS rerated the heater using ULNB to reduce NOx emissions. The burners are fired vertically
upwards and the NOx emissions are 0.018 lbs/MMBtu. The burners were housed in a
common air plenum with a central air intake. The air intake was provided with a pneumatic
damper.
• Install New Convection Module:
Existing convection section efficiency was very low due to a high flue gas temperature
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26. Furnace Improvements
Low Cost Solutions for Fired Heaters
leaving the section. The flue gas temperature decreased to 520o F from 680o F by replacing
the convection section. FIS supplied and installed an upgraded convection section.
• Installation of New Stack and Damper:
FIS replaced the existing stack and installed O2 and temperature indicators for better control
of the Oxygen levels and temperatures exiting the stack. The new stack was provided with
connected ladders and platforms. The existing stack did not have a damper for draft control.
The new stack damper is pneumatically operated. Minimum limit stop has been provided on
linkage side of damper frame so as to prevent it from being fully closed. A position
transmitter has been provided to know the damper opening position. The stack damper is
provided to ensure that the draft at arch is maintained at the design level of (-) 0.1” WC
under all operating conditions.
Before After
Revamp Revamp
Duty (MMBtu/hr) 55 60
Efficiency (%) 66 86.2
Firing Rate (MMBtu/hr) 83.3 69.6
Energy savings ($/year) - 782,093
Payback Period (Years) - 1.72
After the revamp, the efficiency increased by 20%. The total cost of the project for the design
services, engineering services, fabrication and installation was $1,560,000. The project payout
was estimated to be less than 2 years. This heater was successfully commissioned in March
2008.
Client ConocoPhillips
Client Contact Mr. Hiren Yagnik
Telephone (618) 255-2534
Location Roxana, IL
•••
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27. Furnace Improvements
Low Cost Solutions for Fired Heaters
Case Study 269
H-28 Vacuum Heater Performance
Improvement Study
A refinery was facing coking problems in their Vacuum Heater.
In addition, they also wanted to revamp the heater to handle
Canadian Crude and reduce NOx emissions. FIS did the process
study and as a result of the study, the client decided to build a
new Vacuum heater with an existing heater foundation. The new
heater is 4 ft wider.
This vacuum heater is a horizontal tube box with a convection
section. It is designed for a heat duty of 43MMBtu/hr. FIS’
scope involves design, engineering, structural analysis and
supply of this heater to the site. The heater has an efficiency of
90%.
It was successfully commissioned in March 2009. The heater
was delivered within 7 months of starting the job.
A few months after the start up, FIS received the following
feedback from the client.
“.. we talked about the performance of the VF4 H28 heater
since startup. It has been fantastic! The stack temperature is
370-380°F and the fuel gas usage has dropped about 40% from
the old heater. This is one of the most •
• • efficient heaters in the
refinery. The NOx stack testing came back 0.026 lb
NOx/MMBtu, which is also outstanding. They are even trying
to reduce the O2 even lower, from 4% to 3%. It's a lot different
when you have a tight firebox. Great job!!!”
-Client
Client ConocoPhillips
Client Contact Mr. Hiren Yagnik
Telephone (618) 255-2534
Location Roxana, IL
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28. Furnace Improvements
Low Cost Solutions for Fired Heaters
•••
Case Study 279
Hot Oil Heater, Wyoming
Furnace Improvements (FIS) was employed to perform
an engineering study on a Hot Oil Heater (HT-501) at a
gas plant.
The heater was originally designed for a 25 MMBtu/hr
duty. FIS analyzed the design and existing condition of
the heater and developed these options:
1. Replacing the heater with a new vertical cylindrical
heater.
2. Replacing the heater with a new cabin heater having
the same plot area as of existing heater.
3. Revamping existing heater
• Replacing the radiant coils, refractory and
radiant tube supports.
• Replacing the existing convection section
with a new improved convection section.
• Replacing burners
The client opted for option 1 and awarded FIS with a
contract for the turnkey supply of new Hot Oil Heater
for their gas plant.
FIS executed the heater process and mechanical design, structural analysis, material
procurement, fabrication and installation of the Hot Oil Heater in 8 months schedule.
FIS also supplied the burner management system and procured all the instrumentation controls of
the heater. The heater was designed for an increased efficiency of 85% and it was commissioned
in August 2007.
Client Devon Energy
Client Contact Mr. Craig Shaw / Mr. Richard Myal
Telephone (307) 857-2291 / (405) 228-8895
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29. Furnace Improvements
Low Cost Solutions for Fired Heaters
Location Riverton, WY
•••
Case Study 280
CDHDS Reboiler Heater (H-60) Efficiency
Improvement Project
Furnace Improvements (FIS) was employed to develop an efficiency improvement scheme for
CDHDS reboiler heater (H-60).
The CDHDS reboiler heater is a vertical cylindrical
natural draft heater built in 2002. The CDHDS reboiler
heater (H-60) was designed for a process duty of
72 MMBtu/hr, with a design efficiency of 81%. The
heater was operating at an efficiency of 79%, with the
flue gas stack temperature of 780°F.
FIS reviewed the design and proposed the following
changes to improve the efficiency:
• Adding six rows of steam generation coil in
convection section
• New stack transition cone
• 25 ft of stack extension
In this scheme, 71,000 lb/hr of 450 # steam condensate
is flashed to 150 # 2 phase, vapor-liquid stream.
Flashing is completed before it enters the convection
section.
The total heat duty of the heater was increased to 82 MMBtu/hr. The extra 10 MMBtu/hr is absorbed
in steam generation coil. Flue gas temperature leaving the stack was reduced at 400°F.
The efficiency of the heater was increased to 90%, which brought energy savings of
approximately USD $ 590,550 per year. The payback period is 1 year 3 months.
This project has been successfully commissioned in October 2007.
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30. Furnace Improvements
Low Cost Solutions for Fired Heaters
Client Valero
Client Contact Mr. Steven Guillory
Telephone (409) 948-7463
Location Texas City, TX •••
Case Study 283
Vacuum Heater Capacity Increase Project
Furnace Improvements (FIS) was employed to
conduct an engineering study for a refinery
vacuum heater (200-H4) in Indiana. As part of
their expansion project, the refinery needed to
increase the capacity of a cabin vacuum heater.
This heater was originally installed in 1949.
FIS developed four modification options to
increase the capacity of the vacuum heater. The
client opted for revamping the radiant section coil,
new burners and a new stack.
With these modifications, the capacity of the
heater was increased from 8,200 to 9,500 BPD.
The Heater was successfully commissioned and is
working with increased capacity since May 2008.
Client CountryMark
Client Contact Mr. Tariq Asrar
Telephone (812) 833-3640 / (812) 838-8186
Location Mt. Vernon, IN
•••
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31. Furnace Improvements
Low Cost Solutions for Fired Heaters
Case Study 286
Hot Oil Heater
Furnace Improvements (FIS) was employed to perform
an engineering study on a Hot Oil Heater (H-3) in
Roxana, IL. FIS submitted the design and was awarded a
contract for the turnkey supply of new Hot Oil Heater for
their BEU unit.
The BEU Heater (H-3) is a natural draft, vertical
cylindrical heater with a radiant section, convection
section and stack. The heater is used to heat hot oil. The
heater is designed for a total heat duty of 165 MMBtu/hr.
FIS executed the heater process, mechanical design,
structural analysis, material procurement and fabrication
of this hot oil heater.
The client requested an expedited delivery for this heater
to meet their turnaround schedule.
• This heater was delivered to the site within 9
months of receipt of order.
• The fabrication was done to such an extent that
there were no structural welds at the site. All the
connections were designed to be bolted
connections.
• This is a 6 pass heater and radiant panels were
designed for each pass to fit in each radiant panel.
• The stack outside diameter is 11’ 3 5/8” and the
height is 97’ 2”. This stack was shipped in two
pieces, which were bolted at the site.
This heater was succesfully commissioned in May 2009.
Client ConocoPhillips
Client Contact Mr. Hiren Yagnik
Telephone (618) 255-2534
Location Roxana, IL
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32. Furnace Improvements
Low Cost Solutions for Fired Heaters
•••
Case Study 287
CO Boiler Convection Replacement
An Illinois refinery had a CO boiler in their Fluid Catalytic Cracking (FCC) Unit. The CO boiler
was more than 40 years old. The CO boiler’s convection section is used to preheat the FCC
charge and also generate superheated steam at 600 psig and 710°F.
The boiler had three main problems:
• Low economizer tube metal temperatures reaching dew point levels
• High super heated steam temperature
• Problems with tube supports in the hottest zone
The refinery approached Furnace Improvements (FIS) to provide a new thermal design for
replacing the convection section of the CO boiler. FIS conducted a detailed operation analysis of
the existing CO boiler and built a model of the existing design. With the model built, we were
able to simulate the current operating conditions and predict the heater performance for the
future operating conditions.
We developed a better design overcoming the drawbacks in the existing CO heater. The
convection section was redesigned to:
• Increase FCC feed flow CO Boiler Convection Section
• Improve CO Boiler efficiency Replacement
• Prevent cold end corrosion of Before After
Item Units
economizer Revamp Revamp
• Eliminate flow distribution Process Heat Duty MMBtu/hr 81.55 104.91
problems Steam Heat Duty MMBtu/hr 100.90 115.92
Process Flow BPD 41,995 48,000
The new design was developed
Stack Temp. °F 636 577
retaining the existing soot blower
Efficiency % 68.0 72.6
locations and platform elevations.
0.55 Million*
Fuel Savings $ / annum
[ $3.0/MM Btu]
It was estimated to save the client almost $550,000 per year. The project was successfully
executed in February 2008.
Client ConocoPhillips
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33. Furnace Improvements
Low Cost Solutions for Fired Heaters
Client Contact Mr. Hiren Yagnik
Telephone (618) 255-2534
Location Roxana, IL •••
Case Study 299
Convection Section Modification in CO
(CCU-1 & CCU-2) Heater for SCR
Installation
A Refinery has CO heater (CCU/2) in their
FCC unit. It is used to combust the FCC off
gas (mainly CO gas) from the spent catalyst
regenerator unit. The hot flue gases
generated from combustion of FCC off gas
are used to preheat the oil and generate
super heated.
The client was installing a new SCR unit
downstream of the CO Heater as a part of
the consent decree agreement to reduce the
NOx emissions. The new SCR requires a
specific flue gas inlet temperature, which
will require reconfiguring the heat transfer
surface in the convection section.
FIS modeled the convection section for 5 proposed cases and provided a revised design. The
proposed cases were so extreme in nature that it was very difficult to meet the flue gas
temperature requirement for all the 5 cases for one design. So, FIS designed the last coil as a trim
coil. The last coil will be use in service when the flue gas temperature exceeds the higher limit
and it will be run dry when the flue gas temperature drops below the lower limit. FIS also
provided a revised configuration for the oil pre heat coil to limit the oil outlet temperature below
730 Deg F to prevent coking.
The client wanted the super heated steam temperature to be close to the design so FIS
reconfigured the super heater surface and provided a revised design. The client approved FIS
design to revamp the convection section. The project was successfully comissioned in August
2009.
Client ConocoPhillips
Client Contact Mr. Hiren Yagnik
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34. Furnace Improvements
Low Cost Solutions for Fired Heaters
Telephone (618) 255-2534
Location Roxana, IL
•••
Case Study 290
NOx Reduction of Six Fired Heaters
Furnace Improvements was requested to develop a NOx reduction study on six heaters. The
client wanted their NOx emissions to be reduced to 0.025 lb NOx/MMBtu. These heaters were
also needed to be rerated for new operating conditions.
FIS analyzed all the heaters thoroughly, evaluated different schemes and arrived at a conclusion
of replacing the existing burners with Ultra Low NOx burners.
• Platformer Heater (009-0920,30,40)
• Preflash Reboiler Heater (004-0095)
• Vacuum Heater (004-0096)
• Cat Cracker Heater (007-0093)
• Charge & Stripper Reboiler Heater (009-0910)
• Charge Heater (012-0090)
Preflash Reboiler
The heater was built in 1979 as a vertical cylindrical
heater with an absorbed duty of 25 MMBtu/hr and a feed
rate of 135,827 lb/hr.
Charge / Stripper Reboiler
The heater was built in 1958 and was revamped in 1979
with 15 burners on the charge side and 13 burners on the
Stripper reboiler side.
The charge heater has an absorbed heat duty of 10.09
MMBtu/hr and a feed rate of 135,501 lb/hr. The stripper
reboiler has an absorbed heat duty of 15.49 MMBtu/hr and a feed rate of 264,494 lb/hr.
Platformer Heater
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35. Furnace Improvements
Low Cost Solutions for Fired Heaters
The Platformer was built in 1979 on process requirements set forth by UOP. This Platformer
Heater is a vertical arbor (“U”) tube heater with 3 radiant sections and a common convection
section and a stack .The heater has an absorbed duty of 115.9 MMBtu/hr.
• The numbers of burners will be increased from 30 to 52.
Vacuum Heater
Vacuum heater is a horizontal tube cabin heater built in 1995. The heater is designed for a feed
rate of 351,000 lb/hr and an absorbed duty of 42 MMBtu/hr. This heater had high stack
temperatures.
• The numbers of burners will be increased from 6 to 9 burners.
Charge Heater
The heater was built as a vertical cylindrical heater in
1964, upgraded in 1979, and purchased, rerated and
relocated from California to El Dorado refinery in 1993.
The heater is designed for a feed rate of 26,930 BPD and
an absorbed heat duty of 26.48 MMBtu/hr.
Cat Cracker Heater
The Cat Cracker was built as a vertical cylindrical heater
in 1978. The heater was designed for a feed rate of 22,570
BPD and an absorbed heat duty of 40 MMBtu/hr.
Client Lion Oil
Client Contact Mr. Jeff Carr
Telephone (870) 864 1240
Location El Dorado, AR
•••
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36. Furnace Improvements
Low Cost Solutions for Fired Heaters
Case Study 296
Hydrogen Heater Capacity Improvement
Project
Furnace Improvements (FIS) carried out a Hydrogen
Heater (77-H-001) revamp project. The Hydrogen
Heater is a vertical cylindrical heater, built in 1990.
The heater was revamped in 2003, for a heat duty of
12.48 MMBtu/hr. The heater was operating at
efficiency of 78% and an absorbed duty of 11.6
MMBtu/hr. The revamp heater design heat duty is
14.77 MMBtu/hr.
Operating data analysis indicated the following:
• Convection section fins are burned out/ fouled,
resulting in higher flue gas temperature leaving
the convection section.
• Flue gas temperature leaving the convection
section increases continuously with time.
Currently, it is around 100ºF higher than the
clean conditions flue gas temperature.
The conventional revamp scheme (to preheat the
feed in the convection section) resulted in very high
fluid pressure drop. High fluid pressure drop was not
feasible.
FIS redesigned the convection section with FIS patented “Split Flow Technology”. In this
scheme the feed was heated parallel in the convection and radiant section. The pressure drop
across the heater reduced even at higher capacity, due to this parallel processing.
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37. Furnace Improvements
Low Cost Solutions for Fired Heaters
Hydrogen Heater Data Comparison
Item Units Design Operating After Revamp
Capacity lb/hr 22,383 16,400 24,560
Absorbed
MMBtu/hr 12.46 11.6 14.77
Duty
Heat Release MMBtu/hr 16.82 14.9 17.17
Stack Temp. °F 796 790 478
Efficiency % 74.1 77.8 86
FIS carried out the entire scope of activities from conceptualization to commissioning of this
heater revamp. The heater was successfully commissioned in May 2009. After revamp, the
thermal efficiency of this heater increased from 78% to 86%.
Client Alon USA
Client Contact Mr. Steve Mattingley / Mr. Jeff Broman
Telephone (432) 263-9333/ (432) 263-9237
Location Big Spring, TX
•••
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38. Furnace Improvements
Low Cost Solutions for Fired Heaters
Case Study 303
Capacity Increase and Efficiency
Improvement in Naphtha Stabilizer Reboiler
A Texan Refinery requested FIS to rerate the NSR for new
process conditions. The natural draft heater is a vertical
cylindrical with convection section and mounted stack. It had
a heat duty of 8.6 MMBtu/hr with an efficiency of 83%.
FIS observed that the firebox was small and volumetric heat
release was high. The proposed process conditions weren’t
feasible with the existing radiant section. Convection section
temperatures were high and the stack height was limiting with
the new firing conditions.
FIS approach was to extend the radiant section and install a
new radiant coil with 50% more radiant area. The heat duty
increase to 10.8 MMBtu/hr and the efficiency went up to 88%
giving fuel savings of US$270,000 per year.
FIS worked on the design, detail engineering, fabrication and
supply of the new convection section, stack and radiant coils.
This project was completed in a fast track and it was
successfully commissioned on September 2009.
Client Alon USA
Client Contact Mr. Steve Mattingley / Mr. Jeff Broman
Telephone (432) 263-9333/ (432) 263-9237
Location Big Spring, TX
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Low Cost Solutions for Fired Heaters
•••
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40. Furnace Improvements
Low Cost Solutions for Fired Heaters
Case Study 314
Capacity Increase for Naphtha Splitter
Reboiler Service
Furnace Improvements (FIS) was employed by a Refinery in
Indiana to carry out a heat duty increase project for the
Naphtha Splitter Reboiler service. Operating heat duty was
around 11.74 MMBtu/hr. This was being supplied by Naphtha
Splitter Reboiler Heater and by Platformer Heater Convection
Coil. Naphtha Splitter Reboiler service heat duty needs to be
increased by 5 MMBtu/hr.
FIS reviewed the design and operating data for the Naphtha
Splitter Reboiler heater (900-H-1) and modeled the heater
operation. Any heat duty increase in this heater is not viable.
FIS reviewed also the design and operating data for Platformer
Heater (300-H1/H2/H3). In this heater there are 3 radiant cells
and a common convection section. It is possible to shift part of
the #1 Inter Heater duty to the radiant cell of the heater and use
part of this convection coil to provide heat duty of Naphtha
Splitter service. This will require an increase in the firing rate
of the Inter Heater cell. It will need new burners of a higher
capacity.
Client has an Old Platformer Charge Heater (900-HXX). The heater was abandoned in the favor
of the new Platformer heater (300-H1/H2/H3). The inspection of the Old Platformer Charge
Heater from outside showed that it is in good condition. FIS proposes using this heater for
providing the required heat duty requirement for Naphtha Splitter Reboiler service.
FIS revamped the old Platformer Charge Heater adding a new radiant section with tubes and
hangers and a small convection section. The stack was reused. The capacity was increase from
8.38 MMBtu/hr (Naphtha Splitter Reboiler) to 20.12 MMBtu/hr (old Platform Charge Heater).
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FIS scope of work includes process design, detail engineering, structural design, mechanical
design, GA drawings, Shop fabrication drawings, erection and commissioning supervision.
The heater was successfully commissioned in November 2009.
Client CountryMark
Client Contact Mr. Tariq Asrar
Telephone (812) 833-3640
Location Mt. Vernon, IN
•••
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42. Furnace Improvements
Low Cost Solutions for Fired Heaters
Case Study 329
NOx Reduction and Capacity Increase of
H-102 and H-205 Heaters
FIS was employed by a texan Refinery to
develop a NOx reduction study for Depantanizer
Reboilers (H-102 and H-205). Client wished to
reduce the NOx emissions from their heaters by
installing Ultra Low NOx Burners. The targeted
NOx emissions from these heaters are 0.035
lb/MMBtu (HHV basis).
Both heaters are vertical cylindrical heaters with
horizontal convection section and a top mounted
stack. They are design for an absorbed heat duty
of 33 and 46 MMBtu/hr.
FIS performed the study and found out that the
convection sections were fouled. FIS suggest to
revamp the heaters with patented “Split Flow
Technology” to increase capacity by 10%. FIS
also suggest to install the ULNB with patented
“inclined firing system” to eliminate fouling
problems.
FIS is currently working on this project. The
heaters will be commissioned on beginning of 2011.
Client Alon USA
Client Contact Mr. Steve Mattingley
Telephone (432) 263-9333
Location Big Spring, TX
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43. Furnace Improvements
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•••
Case Study 333
Capacity Increase on CDU-2; Crude &
Vacuum Heaters (11/12-F-01)
Furnace Improvements (FIS) was employed by an Indian
Refinery at Visakhapatnam, to provide recommendations
to increase the capacity of the Crude Heater (11-F-01)
and Vacuum Heater (12-F-01) by 15%.
The crude heater was commissioned in 1985 for a heat
duty of 60 MMBtu/hr. The existing heater was operating
at a thermal efficiency of around 83% which client
wished to improve. The average flue gas temperature
leaving the stack was around 342°C. This was 110°C
higher than the design stack temperature of 230°C.
The vacuum heater was commissioned in 1985 for a heat
duty of 184 MMBtu/hr. The existing heater was
operating at a thermal efficiency of around 83% and the
client wished to improve the same. The average flue gas
temperature leaving stack was around 308°C. This was
78°C higher than the design stack temperature of 230°C.
The client was already planning to install a new in-kind
convection section, new stack, and a new tight shut-off
damper during the forthcoming shutdown. FIS analyzed
the design of the Crude Heater (11-F-01) and developed a
scheme to increase the capacity and improve the
efficiency of both Heaters.
FIS proposed to add a new convection section below the
new-in kind convection for both heaters. The proposed
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44. Furnace Improvements
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convection will increase the absorbed duty across the convection and will help in reducing the
stack temperature to around 276°C in crude heater and 165°C for vacuum heater.
The results in both heaters were:
Capacity Increase by 15%
Heat duty Increase by 15%
Efficiency Improve to >90%
Stack Temperature reduction
The heaters were successfully commissioned on July 2010.
Client HPCL
Client Contact Mr. S. Bharathan
Telephone (+)91-891-2894814
Location Visakhapatnam, India
…
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45. Furnace Improvements
Low Cost Solutions for Fired Heaters
Case Study 335
Platformer Heaters Capacity Improvement
and NOx Reduction Project
Furnace Improvements (FIS) was
employed to re-rate Heater process using
Low NOx Burners and increase the
Capacity on Platformer Heaters (H-4 /
H-5).
The heaters were originally built in
1959. The heaters were changed to
forced draft in 1977. Common air pre-
heater, induced draft and forced draft fan
were added to pre-heat the combustion
air. Process fluid is heated in radiant
sections. Convection section is used for
steam generation.
Heaters design capacity is 32 MBPD. The client wanted to revamp the heaters for a higher
capacity of 40 MBPD.
The conventional revamp option has following disadvantages:
• Very high cost
• Requires large size manifolds and piping
• Total pressure drop was very high
FIS’ recommended increasing the capacity of the heater using our patented “Split Flow
technology”.
Advantages of revamped design based on split flow are as follows:
• Lower heat flux
• Lower firing rates
• Lower pressure drop
• No radiant section modification
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46. Furnace Improvements
Low Cost Solutions for Fired Heaters
Design Heat Revamp Heat Extra Duty
Heater Section Duty Duty Required
MMBtu/hr
Process Duty
H-4 73.8 82.7 8.9
H-5 72.0 80.5 8.5
H-6 37.5 42.1 4.6
Total 183.3 205.3 22.0
Steam
80.5 51.4 -
Generation
Firing Rate 292.2 283.7 (-)8.5
The process heat duty increased by 22.0 MMBtu/hr. The revamp heaters firing rate shall be 8.5
MMBtu/hr lower than existing design. The new design reduces the air preheat temperature to
270°F from operating temperature of 600-700°F.
FIS carried out the entire scope of activities from conceptualization to commissioning of these
heaters. The project is currently in the execution phase. It is schedule to be commissioned on first
quarter of 2011.
Client ConocoPhillips
Client Contact Mr. Hiren Yagnik
Telephone (618) 255-2534
Location Roxana, IL
•••
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47. Furnace Improvements
Low Cost Solutions for Fired Heaters
Case Study 338
Performance Improvement Project on 3
Platform Heaters
A Wyoming Refinery approached Furnace Improvements (FIS) to carry out an engineering study
for a capacity increase of 3 platformer heaters. The three heaters (H-1003/4/5) were built by
Radco in 1990 and were relocated in 2006 to the Refinery. The middle heater (#1 Reheater) has a
common convection and stack for all three heaters.These heaters are draft limiting. The heaters
are not able to achieve the desired throughput.
FIS analyzed the existing design data and drawings of the Heaters (H-1003/4/5). The
observations are as follows:
• The existing heaters are deficient in design. Arch pressure is positive on all three heaters
at design conditions. The arch pressure is (+)0.603 in WC, (+)0.103 in WC and (+)0.123
in WC for H-1003, H-1004 & H-1005 heaters respectively.
In this study, FIS proposes 5 recommendations for the revamp of Charge Heater (H-1003), #1
Reheater (H-1004) and #2 Reheater (H-1005). The recommendations are based on improving the
draft in all the three heaters. FIS also proposes a recommendation for increasing the capacity of
the heaters to the target capacity.
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48. Furnace Improvements
Low Cost Solutions for Fired Heaters
Client chose the stack modification as a revamp option. FIS carried the following major
modifications:
• The existing stack and transition cone shall be replaced with a new stack and new
transition cone.
• The new stack shall be wider and taller than the existing stack. The new stack length shall
be 95 ft and 7’-6” outside metal diameter.
• The new stack will have new dampers (4 blades) and platforms.
FIS scope of work included process design, detail engineering, structural design, mechanical
design, GA drawings, Shop fabrication drawings, and supply of new transition cone, stack and
platforms.
Client Sinclair
Client Contact Mr. Mike Palumbo
Telephone (307) 328-3549
Location Casper, WY
…
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49. Furnace Improvements
Low Cost Solutions for Fired Heaters
Case Study 339
Capacity Improvement for FRE-APS and
FRE-VPS Heaters (31/32-F-01)
FIS carried out a Crude Heater Capacity
Improvement project for an Indian Refinery
in Mumbai. The Client wanted to increase
the heater capacity by 15% with a thermal
efficiency of more than 90%.
FIS proposed addition of a small convection
section on top of the existing heater
convection section and addition of burners
to the heater. The convection section had a
coil for vacuum heater as well and the
capacity of vacuum heater was increased by
15% too.
The study was carried out in 2 weeks and
the detail engineering was carried out in 8
weeks. The heater was successfully
commissioned on May 2010.
Client HPCL
Client Contact Mr. Anamitra Upadhya
Telephone (+)91-22-25076496
Location Mumbai
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